Reliability of large superconducting magnets through design

As superconducting magnet systems grow larger and become the central component of major systems involving fusion, magnetohydrodynamics, and high-energy physics, their reliability must be commensurate with the enormous capital investment in the projects. Although the magnet may represent only 15% of the cost of a large system such as the Mirror Fusion Test Facility, its failure would be catastrophic to the entire investment. Effective quality control during construction is one method of ensuring success. However, if the design is unforgiving, even an inordinate amount of effort expended on quality control may be inadequate. Creative design is the most effective way of ensuring magnet reliability and providing a reasonable limit on the amount of quality control needed. For example, by subjecting the last drawing operation is superconductor manufacture to a stress larger than the magnet design stress, a 100% proof test is achieved; cabled conductors offer mechanical redundancy, as do some methods of conductor joining; ground-plane insulation should be multilayered to prevent arcs, and interturn and interlayer insulation spaced to be compatible with the self-extinguishing of arcs during quench voltages; electrical leads should be thermally protected; and guard vacuum spaces can be incorporated to control helium leaks. Many reliable design options are known to magnet designers. These options need to be documented and organized to produce a design guide. Eventually, standard procedures, safety factors, and design codes can lead to reliability in magnets comparable to that obtained in pressure vessels and other structures. Wihout such reliability, large-scale applications in major systems employing magnetic fusion energy, magnetohydrodynamics, or high-energy physics would present unacceptable economic risks